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HACCP is a tool that focuses on prevention rather than relying on end-product testing. HACCP can be applied through the food chain from primary production to final consumption and its implementation is guided by scientific evidence of risks to human health.

This capability is reviewed by an independent third party prior to any certifications being issued. This is where the value in the certification lies. Consumers and customers can take assurance that the processes in place meet the requirements of established best practice.

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HACCP Essentials

The HACCP Essentials course is designed to provide a basic and contextualised introduction to the HACCP principles and key food safety practices. Emphasis is placed on practical application by considering how HACCP may apply to your business.

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7 Key Princples of HACCP Certification

Hazard Analysis (HA) – HACCP Principle 1

Conduct a hazard analysis

The HA is used to identify potential microbiological, physical, chemical and allergen hazards that may be reasonably expected to occur at each process step. Allergen cross contamination risk is also included. Regulatory / legal and quality hazards and issues at each step shall also be considered.

The HA includes:

The likely occurrence of hazards and severity / consequence of their adverse health effects or effect on product quality or regulatory compliance

Determination of CCPs – HACCP Principle 2

All hazards at each process step identified during the HA shall be considered in sequence and categorised giving a Risk Rating. If there are hazards at particular steps that are deemed as significant, then it needs to be determined if the step is a Critical Control Points (CCP), Quality Control Points (QCP) or Regulatory Control Points (RCP). Steps that are not a CCP / QCP or RCP but still need to be controlled are control points (CP) and are to be controlled through the established Food Safety & Quality Program.

CCP Critical Limits – HACCP Principle 3

Establish the Critical Control Points (CCP’s)

Critical Limits separate acceptability from unacceptability. CCPs are based on:

Established food safety principles or published research

Legislative requirements

CCPs shall be measurable/quantitative. Where possible, Action Limits shall be set that allow sufficient time for corrective actions to be taken before CCP critical limits are breached. The accuracy / precision / tolerance of monitoring equipment shall be taken into account when setting critical limits and action limits.

CCP Monitoring – HACCP Principle 4

Establish a system to monitor control of the CCP.

Monitoring procedures are the planned sequence of observations or measurements of CCP control measures. Monitoring systems shall be able to detect loss of control at the CCP, and shall provide this information in time for corrective action to be taken to regain control of the process, and to identify, segregate and reject product before it is dispatched.

The documented monitoring system for each CCP shall define:

Responsibility – job title of the individual who will carry out the monitoring

Frequency – if not continuous then at a frequency sufficient to ensure that the CCP is under control.

Method – detailed specification or procedure

Records to be kept – include action limits and critical limits, result of monitoring activity, signature of responsible person and verification countersignature.

Corrective Actions – HACCP Principle 5

Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under control.

As with any control process corrective actions need to be taken when monitoring indicates a trend towards loss of control (action limits breached) or a breach of CCP critical limits. The corrective actions will differ slightly depending on which limit is breached:

Where Action limits are breached corrective actions should include:

Immediate action to re-establish control before the deviation leads to a CCP breach

Responsibility for the corrective action

Where Critical limits are breached corrective actions should include:

Immediate action to re-establish control

Identification of all product produced since critical limit was breached (since last in control monitoring result)

Disposition of affected product

Responsibility for the corrective action

HACCP Plan Verification – HACCP Principle 6

Establish procedures for verification to confirm that the HACCP system is working effectively

As corrective actions are implemented it is important that they are verified to ensure they are achieving the desired results. Verification to confirm the HACCP system is working effectively shall include:

Microbiological and chemical testing (where applicable) to confirm CCPs, QCPs and RCPs are in control. The schedule includes the type and frequency of testing which has been determined by the risk nature of the products and processes, and covers all finished products.

Shelf-life validations covering both microbiological and sensory testing (where applicable). The schedule includes the type and frequency of testing.

Physical assessments of products against specifications. Methods for assessment, responsibilities and frequency of assessment are defined.

12 Steps for the application of HACCP

12 steps for the application of HACCP

In order to implement HACCP there are 12 steps that should be followed:

Assemble a HACCP team – made up of those people with the required knowledge and expertise for the development of an effective HACCP plan (which may include outside resources). It is important that this team has undergone the appropriate HACCP training.

Describe the product – this should include the compositions, physical/chemical structure, treatments, and packaging, durability and storage conditions of the product.

Identify intended use – the expected uses of the product by the end user or consumer.

Construct flow diagrams – should cover or the specific steps in the operation for a specific product including the steps preceding and following the specified operation.

On-site confirmation of flow diagrams – this is to be done by a person with sufficient knowledge of the processing operation.